US6004648AExpiredUtility

Veneer laminate and method of manufacture

63
Assignee: ARKANSAS FACE VENEER CO INCPriority: Feb 7, 1997Filed: Feb 7, 1997Granted: Dec 21, 1999
Est. expiryFeb 7, 2017(expired)· nominal 20-yr term from priority
Inventors:Jonathan Snyder
Y10T156/1062Y10T156/1089B27D 1/005B32B 7/12B27M 1/00Y10T428/24058B32B 21/14Y10T428/24132Y10T428/24066Y10T428/24091Y10T428/2495Y10T428/24942
63
PatentIndex Score
36
Cited by
15
References
30
Claims

Abstract

A two-ply or even-ply veneer laminate panel created by the steps of: pre-flexing a substrate veneer ply sufficiently to substantially break the grains of the substrate ply, and bonding the substrate ply to a face veneer ply. Preferably, the substrate ply is pre-flexed in a direction parallel to the direction that the grains of the substrate ply run. And preferably, the grains of the face ply are oriented in a substantially perpendicular direction to the grains of the substrate ply.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
       1. A veneer laminate comprising: a veneer substrate ply having long grain fibers running in a first direction; and   a veneer face ply bonded to said substrate ply, said face ply having a grain running in a second direction;   wherein bonds between said long grain fibers of said substrate ply are substantially broken or weakened, while said grain of said face ply is not broken, thereby minimizing warping of said veneer laminate.   
     
     
       2. The veneer laminate of claim 1, wherein second direction is substantially non-parallel to said first direction. 
     
     
       3. The veneer laminate of claim 2, wherein: said substrate ply has an inner surface facing said face ply;   said face ply has an inner surface facing said substrate ply; and   a layer of adhesive is positioned between said face ply inner surface and said substrate inner surface.   
     
     
       4. The veneer laminate of claim 3, wherein at least one of said substrate inner surface or said face ply inner surface is substantially coated with said adhesive. 
     
     
       5. The veneer laminate of claim 4, wherein said substrate ply is substantially smooth, resulting from a sanding operation performed after pre-flexing the ply. 
     
     
       6. The veneer laminate of claim 5, wherein said substrate ply has a moisture content of approximately 6% immediately prior to being bonded with said face ply. 
     
     
       7. The veneer laminate of claim 1 wherein: said substrate ply has a thickness ranging from approximately 0.907 millimeters (1/28 inches) to 4.233 millimeters (1/6 inches); and   said face ply has a thickness ranging from approximately 1.588 millimeters (1/16 inches) to 0.462 millimeters (1/55 inches).   
     
     
       8. The veneer laminate of claim 1, wherein said second direction is substantially perpendicular to said first direction. 
     
     
       9. A method for constructing a veneer laminate comprising the steps of: flexing a substrate ply, having grains running in a first grain direction, sufficiently to substantially break the grains of the substrate ply and minimize warping of said veneer laminate; and   after said flexing step, bonding the substrate ply to a veneer face ply, the face ply having unbroken grain running in the second direction.   
     
     
       10. The method of claim 9, wherein the face ply has grains running in a grain direction, and the method further comprises the step of orientating the grain direction of the face ply to be substantially non-parallel to the grain direction of the substrate ply. 
     
     
       11. The method of claim 10, further comprising the step of smoothing a surface of the substrate ply between said flexing and said bonding steps. 
     
     
       12. The method of claim 10, wherein the substrate ply has an inner surface for facing the face ply and the face ply has an inner surface for facing the substrate ply, and the method further comprises the step of applying an adhesive to at least one of the substrate ply inner surface or the face ply inner surface. 
     
     
       13. The method of claim 10, wherein the substrate ply has an inner surface for facing the face ply and the face ply has an inner surface for facing the substrate ply, and the method further comprises the step of positioning a layer of adhesive between the substrate ply inner surface and the face ply inner surface. 
     
     
       14. The method of claim 9, wherein said flexing step involves flexing the substrate ply in a direction substantially parallel to the grain direction of the substrate ply. 
     
     
       15. The method of claim 14, wherein said flexing step involves flexing the substrate on a flexing machine. 
     
     
       16. The method of claim 9, further comprising the step of reducing the moisture content of the substrate ply to about 6% before said bonding step. 
     
     
       17. The method of claim 9, wherein: the substrate ply has a thickness ranging from approximately 0.907 millimeters (1/28 inches) to 4.233 millimeters (1/6 inches); and   the face ply has a thickness ranging from approximately 1.588 millimeters (1/16 inches) to 0.462 millimeters (1/55 inches).   
     
     
       18. The method of claim 9, wherein the substrate ply has an outer surface opposite the inner surface of the substrate ply and the face ply has an outer surface opposite the inner surface of the face ply, and said bonding step includes the steps of: applying approximately 105,487 kg/m 2  (150 lbs/in 2 ) of pressure to the outer surfaces of the face ply and the substrate ply; and   heating the face ply and the substrate ply to approximately 135° C. to 147° C. (275° F. to 300° F.).   
     
     
       19. The method of claim 9, wherein the face ply has grains running in a grain direction, and the method further comprises the step of orientating the grain direction of the face ply to be substantially perpendicular to the grain direction of the substrate ply. 
     
     
       20. The method of claim 9, wherein the face ply has grains running in a grain direction, and the method further comprises the step of orientating the grain direction of the face ply to be substantially parallel to the grain direction of the substrate ply. 
     
     
       21. A veneer laminate product created by a process including the steps of: flexing a substrate ply, having grains running in a first grain direction, sufficiently to substantially break the grains of the substrate ply and minimize warping of said veneer laminate; and   after said flexing step, bonding the substrate ply to a veneer face ply, the face ply having unbroken grain running in the second direction.   
     
     
       22. The veneer laminate product of claim 21, wherein the face ply has grains running in a grain direction, and the process further includes the step of orientating the grain direction of the face ply to be substantially non-parallel to the grain direction of the substrate ply. 
     
     
       23. The veneer laminate product of claim 22, wherein said flexing step involves flexing the substrate ply in a direction substantially parallel to the grain direction of the substrate ply. 
     
     
       24. The veneer laminate product of claim 23, wherein the substrate ply has an inner surface for facing the face ply and the face ply has an inner surface for facing the substrate ply, and the process further includes the step of applying an adhesive to at least one of the substrate ply inner surface or the face ply inner surface. 
     
     
       25. The veneer laminate product of claim 23, wherein the substrate ply has an inner surface for facing the face ply and the face ply has an inner surface for facing the substrate ply, and the process further includes the step of positioning a layer of adhesive between the substrate ply inner surface and the face ply inner surface. 
     
     
       26. A veneer laminate consisting essentially of: a veneer substrate ply, having a grain running in a first direction and a thickness ranging from approximately 0.907 millimeters (1/28 inches) to 4.233 millimeters (1/6 inches); and   a veneer face ply bonded to said substrate ply, and having a grain running in a second direction, and a thickness ranging from approximately 1.588 millimeters (1/16 inches) to 0.462 millimeters (1/55 inches);   wherein said grain of the substrate ply is broken, thereby minimizing warping of said veneer laminate; and   wherein said the grain face ply is not broken.   
     
     
       27. The veneer laminate of claim 26, wherein said second direction is substantially non-parallel to said first direction. 
     
     
       28. A decorative veneer laminate panel comprising: a veneer substrate ply, having a grain running in a first direction; and   a decorative veneer face ply bonded to said substrate ply, said face ply having a grain running in a second direction;   wherein said grain of said substrate ply is broken, while said grain of said face ply is not broken.   
     
     
       29. The decorative veneer laminate panel of claim 28 wherein: said substrate ply has a thickness ranging from approximately 0.907 millimeters (1/28 inches) to 4.233 millimeters (1/6 inches); and   said face ply has a thickness ranging from approximately 1.588 millimeters (1/16 inches) to 0.462 millimeters (1/55 inches).   
     
     
       30. The decorative veneer laminate panel of claim 29, wherein said second direction is substantially non-parallel to said first direction.

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